The XDEM Multi-physics and Multi-scale Simulation Technology: Review on DEM-CFD Coupling, Methodology and Engineering Applications

The XDEM multi-physics and multi-scale simulation platform roots in the Ex- tended Discrete Element Method (XDEM) and is being developed at the In- stitute of Computational Engineering at the University of Luxembourg. The platform is an advanced multi- physics simulation technology that combines flexibility and versatility to establish the next generation of multi-physics and multi-scale simulation tools. For this purpose the simulation framework relies on coupling various predictive tools based on both an Eulerian and Lagrangian approach. Eulerian approaches represent the wide field of continuum models while the Lagrange approach is perfectly suited to characterise discrete phases. Thus, continuum models include classical simulation tools such as Computa- tional Fluid Dynamics (CFD) or Finite Element Analysis (FEA) while an ex- tended configuration of the classical Discrete Element Method (DEM) addresses the discrete e.g. particulate phase. Apart from predicting the trajectories of individual particles, XDEM extends the application to estimating the thermo- dynamic state of each particle by advanced and optimised algorithms. The thermodynamic state may include temperature and species distributions due to chemical reaction and external heat sources. Hence, coupling these extended features with either CFD or FEA opens up a wide range of applications as diverse as pharmaceutical industry e.g. drug production, agriculture food and processing industry, mining, construction and agricultural machinery, metals manufacturing, energy production and systems biology

Determination of Kinetic Parameters for Heterogeneous Reaction System Employing Discrete Element Methods under HPC Platforms

The complex processes of heterogeneous reactions of granular materials such as occurring during metals-ore reduction or biomass gasification involve numerous physical phenomena. The combination of elevated temperature, complex flow, aggressive atmosphere and heterogeneous chemistry make it difficult to study these industrial processes. One of the most important aspects f heterogeneous reactions is to understand and quantify the evolution of the different transformations. For instance, during metal-oxides reduction processes, it is of high importance to quantify the rate at which the pure metal is formed. Nevertheless, it is almost impossible, by experimental means only, to separately observe, accurately quantify and gain insight into these mingled nonlinear physical and chemical processes. In the last decade, numerical simulation tools for particulate processes, such as the eXtended Discrete Element Method (XDEM), have become indispensable to study complex systems without the need of costly experimental practices. In the past, the XDEM has been employed to predict the reduction of tungsten trioxide (WO 3) in dry hydrogen (H2) atmospheres [1] and reduction of iron ores [2]. In the before-mentioned research works, it was employed kinetic data extracted from literature. On one hand, in these processes the kinetic data differ from each other. This is due to the fact that the experimental data in the literature is interpreted with lumped models and empirical models bonded to the specific experimental conditions. On the other hand, advanced simulation tools, such as XDEM, account for all the influencing phenomena (e.g. species and energy distribution, flow conditions, particles shape, rheological properties) constantly interacting in time and space. In these advanced simulation tools, each particle is treated and solved as individual entities and an accurate prediction of the species formation and transport in time and space is provided. Thus, in such advanced numerical tools, the reaction rate parameters representative of the kinetics alone of the involved chemical reactions must be employed. In this contribution, two XDEM simulation case studies accounting for the industrial reduction of WO 3 are presented. The first case study is employed to determine the reaction rate parameters of the four prevalent reduction steps (WO 3↔WO2.9↔WO2.72↔WO2↔W) upon the H 2 reduction of O3. Where the reaction rates are modeled following an Arrhenius law with two parameters per step i.e. pre-exponential factor and activation energy). The constituted optimization problem of minimization of error of the XDEM simulations vs experimental data, implemented and solved in a High Performance Computing (HPC) cluster, is presented and discussed. The determined parameters are later assessed by comparison to a secondly presented case study

A Discrete-Continuous Method for Predicting Thermochemical Phenomena in a Cement Kiln and Supporting Indirect Monitoring

Thermochemical phenomena involved in cement kilns are still not well understood because of their complexity, besides technical difficulties in achieving direct measurements of critical process variables. This article addresses the problem of their comprehensive numerical prediction. The presented numerical model exploits Computational Fluid Dynamics and Finite Difference Method approaches for solving the gas domain and the rotating wall, respectively. The description of the thermochemical conversion and movement of the powder particles is addressed with a Lagrangian approach. Coupling between gas, particles and the rotating wall includes momentum, heat and mass transfer. Three-dimensional numerical predictions for a full-size cement kiln are presented and they show agreement with experimental data and benchmark literature. The quality and detail of the results are believed to provide a new insight into the functioning of a cement kiln. Attention is paid to the computational burden of the model and a methodology is presented for reducing the time-to-solution and paving the way for its exploitation in quasireal-time, indirect monitoring

A Discrete-Continuous Method for Predicting Thermochemical Phenomena in a Cement Kiln and Supporting Indirect Monitoring

Thermochemical phenomena involved in cement kilns are still not well understood because of their complexity, besides technical difficulties in achieving direct measurements of critical process variables. This article addresses the problem of their comprehensive numerical prediction. The presented numerical model exploits Computational Fluid Dynamics and Finite Difference Method approaches for solving the gas domain and the rotating wall, respectively. The description of the thermochemical conversion and movement of the powder particles is addressed with a Lagrangian approach. Coupling between gas, particles and the rotating wall includes momentum, heat and mass transfer. Three-dimensional numerical predictions for a full-size cement kiln are presented and they show agreement with experimental data and benchmark literature. The quality and detail of the results are believed to provide a new insight into the functioning of a cement kiln. Attention is paid to the computational burden of the model and a methodology is presented for reducing the time-to-solution and paving the way for its exploitation in quasi-real-time, indirect monitoring

XDEM for Tuning Lumped Models of Thermochemical Processes Involving Materials in the Powder State

Processes involving materials in gaseous and powder states cannot be modelled without coupling interactions between the two states. XDEM (Extended Discrete Element Method) is a valid tool for tackling this issue, since it allows a coupled CFD- DEM simulation to be run. Such strength, however, mainly finds in long computational times its main drawback. This aspect is indeed critical in several applications, since a long computational time is in contrast with the increasing demand for predictive tools that can provide fast and accurate results in order to be used in new monitoring and control strategies. This paper focuses on the use of the XDEM framework as a tool for fine tuning a lumped representation of the non-isothermal decarbonation of a CaCO3 sample in powder state. The tuning of the lumped model is performed exploiting the multi-objective optimization capability of genetic algorithms. Results demonstrate that such approach makes it possible to estimate fast and accurate models to be used, for instance, in the fields of virtual sensing and predictive control